Channel system for factory built structures

ABSTRACT

A channel system for a support of a factory built building is provided. The channel system allows the support of a building to be easily and quickly assembled. In one construction, a first channel member has a receiving cavity extending in a longitudinal direction that is substantially parallel to a longitudinal axis of the first channel member. A second channel member is configured to be slidably received in the receiving portion of the first channel member.

FIELD OF THE INVENTION

The present invention relates to factory built residential and commercial structures, and more particularly, to a channel system for a support structure for factory built residential and commercial buildings.

BACKGROUND OF THE INVENTION

Factory built residential and commercial buildings have become increasingly popular. As the cost of new construction rises, the relatively lower cost of factory built residential and commercial buildings has attracted many new buyers. Similarly, the design and use of these buildings has changed over the past years. These new designs and uses have made factory built buildings more aesthetically attractive to consumers. Factory built buildings are now widely used in place of traditionally-styled buildings including residential housing, office buildings, such as permanent and portable office buildings, classrooms and transportable hospitals.

As used herein, the phrase “factory built buildings” includes, but is not limited to, permanent “traditionally styled” manufactured structures such as those mentioned above and other manufactured buildings or manufactured homes where the manufactured structure is trucked to the building site on flatbed trailers or the like. The phrase “factory built buildings” also encompasses structures that can be readily moved including transportable office buildings, hospitals and residential housing commonly referred to as “trailer homes.” Furthermore, modular structures including modular office buildings and modular homes are also encompassed by the term “factory built buildings” as sections of these structures are built at an offsite location, such as a factory, and then transported to a site for assembly as a unitary structure.

Factory built buildings are traditionally built upon a frame containing two or more longitudinal members and/or several transverse beams that support the floors of the building. Support systems for these factory built buildings typically include concrete blocks or a plurality of support stands placed under the frame for supporting it and securing it to a type of foundation. Skirting, extending from the factory built building's rim joist to a point within the ground, is commonly used to secure and hide the foundation support system and provide a more aesthetic appearance. However, conventional foundation support and skirting systems may not provide adequate support to the factory built building in response to the lateral forces created by heavy winds, seismic activities or heavy snow. Unfortunately, those systems that may provide adequate support can be costly to produce and install. Additionally, these systems may be aesthetically unattractive. Further, when a cement foundation/footing is poured for aesthetic purposes, the poured concrete must be allowed to set at the job site, thereby delaying the assembly of the building at the job site.

It is also difficult to back-fill soil against conventional skirting and supporting systems for factory built buildings. It is the ability to back-fill dirt and soil against the skirting that helps to give a factory built building the appearance of a site built home. However, if the support assembly of the skirting and supporting system does not provide sufficient structural integrity to the skirting so that the skirting can withstand significant lateral loads, the skirting may fail during the back-filling process. More seriously, if either the skirting or support assembly fails, the factory built building may move during the back-filling process and/or support stands of the support assembly attached to the factory built building may begin to bend and fail before the factory built building is ever occupied. This would present significant dangers to the occupants of the factory built building.

There is a need in the art for an apparatus useable with factory built buildings to help anchor the building during seismic activities, heavy winds, heavy snows and back-filling and provide ease of assembly.

SUMMARY OF THE INVENTION

The present invention pertains to a channel system for a support of a factory built building. The channel system allows the support of a building to be easily and quickly assembled.

In one aspect, a channel system for a support of a factory built building includes a first channel member with a receiving cavity extending in a longitudinal direction that is substantially parallel to a longitudinal axis of the first channel member. A second channel member is configured to be slidably received in the receiving portion of the first channel member.

In one aspect, a channel system for a support of a factory built building includes a system a first channel member having a first leg and a second leg collectively defining an L-shape configuration. The first leg includes a first receiving member extending generally parallel to the second leg. The first leg may include a second receiving member. The first receiving member and the second receiving member collectively define a receiving cavity of the first channel member. A second channel member of the channel system is configured to matingly engage the first channel member in the receiving cavity.

In one aspect, a channel system for a support of a factory built building includes a system a first channel member having a base and rear face which collectively define an L-shape arrangement. The base includes a first receiving member extending from a bottom surface. The base may include a second receiving member. The first receiving member and the second receiving member collectively define a receiving groove of the first channel member. A second channel member of the channel system is configured to matingly engage the first channel member in the receiving groove.

The above and other aspects, features and advantages of the present invention will be readily apparent and fully understood from the following detailed description illustrative embodiments in conjunction with the accompanying drawings, which are included by way of example, and not by way of limitation with regard to the claimed invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a schematic section view of a support system installation for a factory installed building utilizing a channel system according to the teaching of the present invention;

FIG. 2 is a perspective view of a first component of a channel system according to the teaching of the present invention;

FIG. 3 is a side elevational view of the first component of the channel system shown in FIG. 2;

FIG. 4 is an enlarged side view of a portion of the first component of the channel system shown in FIG. 2;

FIG. 5 is a front elevational view of the first component of the channel system shown in FIG. 2;

FIG. 6 is a rear elevational view of the first component of the channel system shown in FIG. 2;

FIG. 7 is a perspective view of a second component of the channel system according to the teaching of the present invention;

FIG. 8 is a side elevational view of the second component of the channel system shown in FIG. 7; and

FIG. 9 is a rear elevational view of the second component of the channel system shown in FIG. 7.

DETAILED DESCRIPTION

FIG. 1 illustrates a skirting and support system 10 for factory built buildings that employ a channel system 100 according to the teaching of the present invention. For ease of explanation, the discussion will relate to two types of factory built buildings, manufactured homes and modular homes. Nevertheless, the application of the skirting and support system 10 and/or the channel system 100 can be used with other types of factory built buildings.

In one example, the skirting and support system 10 comprises a perimeter skirting assembly 20 and a support assembly 30. The support assembly 30 includes at least one support stand 40 and at least one perimeter load bearing footing 50. A wooden block 42 is provided to the top of the support stand 40 in order to carry the load of two to three floor joists 62 of the factory built structure. The skirting assembly 20 includes at least one elongated skirting panel 22. Footing 50 has an elongated slot 52 which extends along the length of the footing 50. The elongated slot 52 receives a portion of the skirting panel 22 and support stand 40 as shown in FIG. 1.

In operation, the support stand 40 is provided on the footing 50 and enables transfer of loads from the exterior of the factory built building to the footing 50 and ground. The elongated slot 52 aligns adjacent skirting panels 22 along the length of the factory built building that they abut. Skirting panel 22 and load bearing footing 50 are constructed of pre-cast concrete material. The footings 50 can include one or more lengths of rebar (not shown) which extend into the ground for additional anchoring. The construction installation includes an earth material backfill 70 and a water proofing barrier 80, such as a polystyrene barrier.

Referring to FIG. 1, channel system 100 is provided on the top of adjacent skirting panels 22 and is attached to the bottom of the rim joist 60. The channel system 100 has a first channel member 103 shown in FIGS. 2-6. The first channel member 103 is attached to the bottom of the rim joist 60. A removable front panel 123 (FIGS. 7-9), referred to herein as a “second channel member”, attaches to the first channel member 103. In operation, the channel system 100 enables ease of site installation of the adjacent skirting panels, including reduced installation time. The skirting panel 22 can be angled (rocked) into slot 52 of the footer 50 from the outside of the stand 40. For ease of explanation, the terms “top”, “bottom”, “front” and “rear” when used to describe channel system 100 relate to an operational position of the channel system when placed on the skirting 20 of the building. Hence, a front view is at a viewing position looking from the exterior of the skirting panel 22. These terms do not limit the use of the channel system 100.

FIGS. 2-6 illustrates an embodiment of the channel system 100. The first channel member 103 has a first leg 105 and a second leg 107 collectively defining an L-shape configuration. The first leg 105 includes a first receiving member 109 extending generally parallel to the second leg 107. The first leg 105 may include a second receiving member 111. The first receiving member 109 and the second receiving member 111 collectively define a receiving cavity 113 of the first channel member 103. In a preferred construction, the receiving cavity 113 is provided in the form of an L-shaped groove. The first leg 105 has a top face 115 and an opposing bottom face 117. The receiving cavity 113 (e.g., groove) is disposed underneath the bottom face 117 of the first leg 105. The second receiving member 111 has a substantially vertical section or portion 112 which extends downward from the bottom face 117. An integral substantially horizontal section or portion 114 extends from the end of the vertical portion 112 and towards first receiving member 109. In one construction, the cavity 113 extends in a longitudinal direction that is substantially parallel to a longitudinal axis a-a of the first channel member 103. The second leg 107 includes a rear face 119 and an interior face 121.

As best seen in FIG. 3, a narrow opening is formed at the receiving cavity 113 entrance and then a wider opening is provided further in the depth of the cavity. A ratio of the width (W1) of the narrow opening to the width (W2) of the wider portion may range from 0.20-0.40 (e.g., ratio of W1/W2). This structure and ratios provides for reduced or eliminated rotation of the second channel member 123 when installed into the cavity 113 to provide a strong assembled channel system 100. The free end 110 of the first receiving member 109 and free end 114 of second receiving member 111 have a generally tapered or rounded arrangement for ease of installation of the second channel member 123.

FIGS. 7-9 illustrate the second channel member 123 of the channel system 100. The second channel member 123 is configured to matingly engage the first channel member 103 in the receiving cavity 113. Second channel member 123 includes a front leg 125 connected to a receiving protrusion 127 that slides and mates in the receiving cavity 113 of the first channel member 103. When the second channel member 123 is mated with the first channel member 103 the assembly forms a U-shaped channel configuration. The second channel member 123 is prevented from rotating about a longitudinal axis parallel to axis a-a. When the receiving protrusion 127 is engaged into the receiving cavity/slot 113, the clockwise rotational movement is stopped by second receiving member 111 of the first channel member 103. Counterclockwise rotation of the second channel member is prevented by the bottom of the first leg 105. This installed configuration provides for a strong channel assembly.

Referring to FIG. 3, the interior surface 119 forming the receiving cavity 113 of the first channel member 103 which transitions from the bottom face 117 has a curved configuration in a concave arrangement. In another configuration, first receiving member 109 has the interior surface 122 formed in the receiving cavity 113 which transitions from the bottom face 117. The interior surface 122 has a curved configuration for a concave arrangement. In one advantage, various point stresses are greatly reduced with the concave arrangement of the interior surfaces 119, 122, rather than a perpendicular configuration. This concave arrangement increases the life of the channel assembly by reducing physical stress and reducing material fatigue of the channel assembly. The one of the interior surfaces 119, 122 could have concaved configuration or both may have a concaved configuration.

In FIG. 8, the free end 130 of the receiving protrusion 127 of the second channel member 123 has a rounded or convex configuration. When the receiving protrusion 127 is slidably installed within the receiving cavity 113, there is an ease of installation and relatively smooth transition of the abutting surfaces e.g., inner surfaces forming the receiving cavity 113 and receiving protrusion 127. In another advantage, the concave-convex relationship of interior surface 119 and free end 130 reduces stress and material fatigue.

The components of channel system 100 are constructed from a non-corrosive material, such as a moldable plastic material. In one construction, the channel system 100 is formed of a polyvinyl chloride (PVC) material. Nevertheless, other materials can be used. Suitable molds can be provided and various lengths of the channel system components can be molded or cut into the needed pieces. The non-corrosive material provides for an extend life of the structure and lowers maintenance cost of the homeowner. Further, a lightweight plastic material of the channel system provides for ease of transport, storage and installation with the site installation crew.

The skirting panels 22 shown in FIG. 1 are precast and can be cured before being transported to the installation site for the factory built building. The skirting panels 22 can be preformed of a lightweight concrete that results in a skirting panel with the external appearance of a poured concrete stem wall. However, unlike a poured concrete wall, the skirting panels 22 do not require time at the installation site to set up and cure. Hence, unlike poured walls, the skirting panels 22 do not delay the installation of the factory built building at the site. Hence, there is synergistic benefit with the use of the channel system 100 and skirting system.

Numerous characteristics, advantages and embodiments of the invention have been described in detail in the foregoing description with reference to the accompanying drawings. However, the disclosure is illustrative only and the invention is not limited to the illustrated embodiments. It will be apparent to persons ordinarily skilled in the art that modifications may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the claims such as to encompass all equivalents, devices, and methods. Therefore, various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention. 

1. A channel system for supporting a factory built building with a skirting panel, said system comprising: a first channel member having a receiving slot extending in a longitudinal direction; and a second channel member for slidably positioning within the receiving slot of the first channel member.
 2. The channel system in accordance with claim 1, wherein the first channel member includes a first leg, and a second leg generally perpendicular to the first leg, wherein the receiving slot is disposed on the first leg.
 3. The channel system in accordance with claim 2, wherein the receiving slot of the first channel member has a general L-shape configuration.
 4. The channel system in accordance with claim 3, wherein the first channel member includes a first portion and a second portion which collectively defined the L-shape configuration of the receiving slot.
 5. The channel system in accordance with claim 4, wherein the first portion is generally parallel to a section of the second portion and the first portion is generally perpendicular to another section of the second portion.
 6. The channel system in accordance with claim 2, wherein the receiving cavity has an entrance that has a narrower width than a width taken at a depth of the cavity.
 7. The channel system in accordance with claim 6, wherein a ratio defined by the width of the entrance to the width taken at a depth of the cavity ranges between 0.20-0.40.
 8. The channel system in accordance with claim 2, wherein the second channel member includes a receiving portion that is configured to fit into the receiving slot of the first channel member.
 9. The channel system in accordance with claim 1, wherein the first channel member and the second channel member are composed of a non-corrosive material.
 10. The channel system in accordance with claim 9, wherein the non-corrosive material is a plastic material.
 11. A channel system for a support of a factory built building, comprising: a first channel member having a base and a face panel which collectively define an L-shape arrangement; and a second channel member of the channel system is configured to removably engage the first channel member in a receiving groove.
 12. The channel system in accordance with claim 11, wherein the base includes a bottom, wherein the base further includes a first receiving member and a second receiving member that extend from the bottom of the base to collectively define the receiving groove.
 13. The channel system in accordance with claim 12, wherein the receiving groove has an L-shape arrangement.
 14. The channel system in accordance with claim 12, wherein the first receiving member is generally parallel to the face panel of the first receiving member.
 15. The channel system in accordance with claim 12, wherein the second channel member is generally parallel to the face panel when engaged in the receiving groove.
 16. The channel system in accordance with claim 11, wherein the first channel member has a longitudinal axis and the second channel member is prevented from rotating about the longitudinal axis.
 17. The channel system in accordance with claim 11, wherein the first channel member and the second channel member are comprise a plastic. 